CD5.242 DC/DC C

CD5.242 DC/DC C
CD5.242
DC/DC Converter; 24V, 5A
CD–Series
DC/DC CONVERTER
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■
Wide Range DC Input (36-60Vdc)
Isolated 24Vdc Output
Efficiency up to 90.3%
Width only 32mm
20% Output Power Reserves
Full Output Power Between -25°C and +60°C
Soft-start Function Included
Minimal Inrush Current Surge
Reverse Input Polarity Protection
3 Year Warranty
1. GENERAL DESCRIPTION
2. SHORT-FORM DATA
The Dimension CD5-Series offers a range of DIN-rail
mountable DC/DC-converters in a very compact
housing.
Output voltage
Adjustment range
Output current
The CD5.242 converts a 48V voltage to a 24V
voltage. The input source can be a battery, a solar
panel or any other 48V sources.
Output power
The CD5.242 includes all the essential basic functions
and has a power reserve of 20% included. This extra
power can be used continuously up to +45°C.
The output is electrically isolated from the input in a
safe way. The input is protected against reversed
voltages and contains a soft start funtion.
24V->24V
CD-Series
Spring-clamp
terminals,
CD5.241-S1 Input-low,
Related products
DC-OK
contacts
24V->24V
24V->12V
CD5.241
CD5.121
Output ripple
Input voltage
DC 24V
23 - 28V
5 – 4.3A
6 – 5.1A
120W
144W
< 50mVpp
DC 48V
Input current
Input inrush current
Efficiency
Losses
Hold-up time
Temperature range
Derating
Dimensions
typ. 2.75A
typ. 0.6A peak
typ. 90.3%
typ. 12.9W
typ. 5.6ms
-25°C to +70°C
3W/°C
32x124x102mm
At 48Vdc input
At 48Vdc input
At 48Vdc input
Operational
+60 to +70°C
WxHxD
UL 60950-1
Class I Div 2,
pending
Ambient <60°C
Ambient <45°C
Ambient <60°C
Ambient <45°C
20Hz to 20MHz
36 to 60Vdc
(30.5 to 36Vdc
with derating)
At 48Vdc input
48V->24V
CD5.242
3. ORDER NUMBERS
DC/DC
Converter
Accessories
CD5.242
4. MARKINGS
Standard unit
18WM
LISTED
IND. CONT. EQ.
ZM1.WALL
ZM11.SIDE
YRM2.DIODE
YR2.DIODE
Wall mount bracket
Side mount bracket
Redundancy module
Decoupling module
UL 508
GL
R
C
182790
US
pending
Marine, pending
EMC, LVD
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
INDEX
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
PAGE
General Description ............................................1
Short-form Data ..................................................1
Order Numbers....................................................1
Markings ..............................................................1
Input Voltage ......................................................3
Soft-start and Input Inrush Current Surge .........4
Output .................................................................5
Hold-up Time.......................................................6
Efficiency and Power Losses................................7
Functional Diagram.............................................8
Reliability .............................................................8
Front Side and User Elements.............................9
Terminals and Wiring..........................................9
EMC....................................................................10
Environment ......................................................11
Protection Features ...........................................12
Safety .................................................................12
Dielectric Strength ............................................12
Approvals...........................................................13
Fulfilled Standards ............................................13
INDEX
21.
22.
23.
24.
25.
PAGE
Used Substances ............................................... 13
Physical Dimensions and Weight ..................... 14
Installation and Operation Instructions .......... 14
Accessory........................................................... 15
Application Notes............................................. 16
25.1. Peak Current Capability ......................... 16
25.2. Back-feeding Loads ................................ 16
25.3. Inductive and Capacitive Loads ............. 16
25.4. Output Circuit Breakers ......................... 17
25.5. Series Operation..................................... 18
25.6. Parallel Use to Increase Output Power . 18
25.7. Daisy Chaining of Outputs..................... 18
25.8. Parallel Use for 1+1 Redundancy........... 19
25.9. Charging of Batteries ............................. 19
25.10. Requirements for the Supplying Source 20
25.11. External Input Protection....................... 20
25.12. Use in a Tightly Sealed Enclosure .......... 20
25.13. Mounting Orientations .......................... 21
INTENDED USE
The DC/DC converter shall only be installed and put into operation by qualified personnel.
This DC/DC converter is designed for installation in an enclosure and is intended for the general use, such as in
industrial control, office, communication, and instrumentation equipment. Do not use this device in aircraft, trains
and nuclear equipment, where malfunctioning of the DC/DC converter may cause severe personal injury or threaten
human life.
TERMINOLOGY AND ABREVIATIONS
PE and
symbol
PE is the abbreviation for Protective Earth and has the same meaning as the symbol
.
Earth, Ground
This document uses the term “earth” which is the same as the U.S. term “ground”.
T.b.d.
To be defined, value or description will follow later.
DC 24V
A figure displayed with the AC or DC before the value represents a nominal voltage with
standard tolerances included.
E.g.: DC 12V describes a 12V battery regardless whether it is full (13.7V) or flat (10V)
24Vac
A figure with the unit (Vdc) at the end is a momentary figure without any additional
tolerances included.
DISCLAIMER
The information presented in this document is believed to be accurate and reliable and may change without notice.
Some parts of this unit are patent by PULS (US patent No 091662,063, Des. 424,529, …).
No part of this document may be reproduced or utilized in any form without permission in writing from PULS GmbH.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
5. INPUT VOLTAGE
Input
Input voltage range
nom.
nom.
typ.
max.
DC 48V
36.0-60.0Vdc
30.5-36.0Vdc
63.0Vdc
Allowed voltage between input
and earth (ground)
max.
max.
60Vdc or
42.4Vac
5Vpp
typ.
typ.
typ.
typ.
typ.
typ.
typ.
max.
typ.
34.5Vdc
30.5Vdc
63.5Vdc
2.75A
670ms
80ms
150ms
500mV
800µF
Allowed input ripple voltage
Turn-on voltage
Shut-down voltage
Input current
Start-up delay
Rise time
Turn-on overshoot
Input capacitance
Continuous operation
Max. 60 seconds or with de-rating, see Fig. 5-2
Absolute maximum continuous input voltage with no
damage to the DC/DC converter. Please note that the unit
can switch off above 60Vdc
47Hz-40kHz, the momentary input voltage must always be
within the specified limits.
Steady-state value, see Fig. 5-1
Steady-state value, see Fig. 5-1
Steady-state value, see Fig. 5-1
At 48Vdc input and output 24V, 5A, see Fig. 5-4
0mF, 24V, 5A, see Fig. 5-3
0mF, 24V, 5A, constant current load, see Fig. 5-3
5mF, 24V, 5A, constant current load, see Fig. 5-3
See Fig. 5-3
External capacitors on the input voltage bus are allowed without any limitations.
Fig. 5-2 Allowable output current below 36V
input voltage
Fig. 5-1 Input voltage range
Rated input range
Output Current
6A
(a)
5
(b)
4
3
1
Input Voltage
0
30
Fig. 5-3 Turn-on behavior, definitions
Intput
Voltage
(a) Ambient < 45°C
(b) Ambient < 60°C
2
63.5Vdc
60.0Vdc
VIN
35.0Vdc
36.0Vdc
30.5Vdc
Turn-on
Shut-down
POUT
32
34
36
38
40Vdc
Fig. 5-4 Input current vs. output load
4A
Input
Current,
typ.
c
Vd
36
:
t
u
I np
Vd c
: 48
t
u
In p
3
- 5%
Start-up
delay
Rise
Time
Overshoot
2
Output
Voltage
1
Output Current
0
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6A
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
6. SOFT-START AND INPUT INRUSH CURRENT SURGE
Inrush current limitation
An active inrush limitation circuit (inrush limiting resistor which is bypassed by a relay contact) limits the input inrush
current after turn-on of the input voltage.
The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Inrush current
max.
typ.
typ.
Inrush energy
Input 48Vdc
0.8Apeak
0.6Apeak
negligible
-25°C to +70°C
-25°C to +70°C
-25°C to +70°C
Fig. 6-1 Input inrush current, typical behavior
Input Current
Input Voltage
Input:
Output:
Ambient:
48Vdc
24Vdc, 5A, constant current load
25°C
Upper curve:
Middle curve:
Lower curve:
Time scale:
Input current 1A / DIV
Input voltage 50V / DIV
Output voltage 20V / DIV
100ms / DIV
Output Voltage
Soft-start function:
After the DC/DC converter is turned on, the internal output current rises slowly to its nominal value. This method
charges the output capacitors (internal and external capacitors) slowly and avoids high input currents during turn-on.
High input currents can produce a high voltage drop on the input wiring (especially with long and thin cables) which
reduces the terminal voltage on the DC/DC converter. If the terminal voltage is below the shut-down voltage, the
DC/DC converter will turn-off and will make a new start-up attempt. This effect is avoided with the integrated softstart function. Please note, that this function increases the rise time of the output voltage by a small amount.
Fig. 6-2 Soft-start behavior
Input:
48Vdc
Output:
24Vdc, 5A, constant current load
Ambient:
25°C
No additional external capacitors
Input Current
Upper curve:
Lower curve:
Time scale:
Input current 2A / DIV
Output voltage 10V / DIV
20ms / DIV
Output Voltage
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
7. OUTPUT
Output voltage
Adjustment range
Factory setting
Line regulation
Load regulation
Ripple and noise voltage
Output capacitance
Output current
Output power
Short-circuit current
nom.
min.
max.
24V
23-28V
30V
max.
max.
max.
typ.
nom.
nom.
nom.
nom.
nom.
nom.
min.
max.
24.1V
25mV
100mV
50mVpp
2200µF
6A
5A
5.1A
4.3A
144W
120W
7A
10A
Guaranteed
At clockwise end position of potentiometer
±0.2%, at full load, cold unit
Input variations between 36 to 60Vdc
Static value, 0A Æ 5A Æ 0A
20Hz to 20MHz, 50Ohm
At 24V, ambient < 45°C, see Fig. 7-1
At 24V, ambient < 60°C, see Fig. 7-1
At 28V, ambient < 45°C, see Fig. 7-1
At 28V, ambient < 60°C, see Fig. 7-1
Ambient < 45°C
Ambient < 60°C
Load impedance 200mOhm, see Fig. 7-1
Load impedance 200mOhm, see Fig. 7-1
Fig. 7-1 Output voltage vs. output current,
typ. (48Vdc input voltage)
Output Voltage
Fig. 7-2 Current limitation vs. input voltage,
typ. (23V constant voltage load)
Output Current
Adjustment
Range
28V
7.0A
6.9
6.8
6.7
6.6
6.5
6.4
6.3
6.2
24
20
16
12
8
4
0
Output Current
0
2
4
6
8
10
Input Voltage
30
12A
36
42
48
54
60Vdc
Peak current capability (up to several ms)
The DC/DC converter can deliver a peak current which is higher than the specified short term current. This helps to
start current demanding loads or to safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the DC/DC converter. During this event, the capacitors
will be discharged and cause a voltage dip on the output. Detailed curves can be found in chapter 25.1.
Peak current voltage dips
typ.
typ.
typ.
from 24V to 17.1V
from 24V to 15V
from 24V to 11V
At 10A for 50ms, resistive load
At 20A for 2ms, resistive load
At 20A for 5ms, resistive load
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
8. HOLD-UP TIME
The input side of the DC/DC converter is equipped with a bulk capacitor which keeps the output voltage alive for a
certain period of time when the input voltage dips or is removed. The bulk capacitor can be discharged by loading
the DC/DC converter on the output side or through a load which is parallel to the input. There is no protection in the
DC/DC converter which prevents current from flowing back to the input terminals. If prevention is needed, an
external diode should be used.
Hold-up Time
typ.
typ.
Input 48Vdc
10.5ms
5.6ms
Input 48Vdc, Output: 24Vdc, 2.5A, see Fig. 8-1
Input 48Vdc, Output: 24Vdc, 5A, see Fig. 8-1
Fig. 8-1 Hold-up time vs. input voltage
Hold-up Time
12ms
10
(a)
8
(b)
(c)
6
4
2
Input Voltage
0
36
40
44
(d)
(a) 24V, 2.5A, typ.
(b) 24V, 2.5A, min.
(c) 24V, 5A, typ.
(d) 24V, 5A, min.
48
52
56Vdc
Fig. 8-2 Shut-down test setup
S1
+
DC
Source
-
DC/DC
Converter
Input
+
Intput
Voltage
S1 opens
+
CD5
Output -
Fig. 8-3 Shut-down behavior, definitions
Load
-
- 5%
Output
Voltage
Hold-up Time
Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on during this time.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
9. EFFICIENCY AND POWER LOSSES
Efficiency
Power losses
typ.
typ.
typ.
typ.
typ.
Fig. 9-1 Efficiency vs. output current at 24V
output voltage and 48V input voltage
Input 48Vdc
90.3%
0.9W
6.9W
12.9W
16.4W
5A, 24V
At no output load
2.5A, 24V
5A, 24V
6A, 24V
Fig. 9-2 Losses vs. output current at 24V
output voltage and 48V input voltage
Efficiency
Power Losses
91%
18W
90
15
89
12
88
9
87
6
3
86
Output Current
85
1
2
3
4
Output Current
0
5
6A
Fig. 9-3 Efficiency vs. input voltage, 24V, 5A
output
0
1
3
4
5
6A
Fig. 9-4 Losses vs. input voltage, 24V, 5A
output
Efficiency
Power Losses
91%
18W
90.5
15
90.0
12
89.5
9
89.0
6
3
88.5
88.0
36
2
Input Voltage
40
44
48
52
Input Voltage
0
56 60Vdc
36
40
44
48
52
56
60Vdc
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
10. FUNCTIONAL DIAGRAM
Fig. 10-1 Functional diagram
Output
Voltage
Regulator
+
-
Input Fuse
&
Input Filter
Chassis
Ground
Reverse
Polarity
Protection
&
Inrush
Limiter
OverTemperature
Protection
Power
Converter
Output
Filter
Output
OverVoltage
Protection
VOUT
+
+
DC
ok
11. RELIABILITY
Input: 48Vdc
Lifetime expectancy
MTBF SN 29500, IEC 61709
MTBF MIL HDBK 217F
min.
min.
min.
min.
169 000h
64 000h
39 000h
181 000h
951 000h
1 560 000h
559 000h
749 000h
40°C, 24V, 2.5A
40°C, 24V, 5A
40°C, 24V, 6A
25°C, 24V, 5A
40°C, 24V, 5A
25°C, 24V, 5A
40°C, 24V, 5A, Ground Benign GB40
25°C, 24V, 5A, Ground Benign GB25
The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the
lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours.
Lifetime expectancy is calculated according to the capacitor’s manufacturer specification. The prediction model allows
a calculation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates
reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily
represent the life of a product.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
12. FRONT SIDE AND USER ELEMENTS
Fig. 12-1
Front side
A
A Output Terminals
Screw terminals
Dual terminals per pole
+
Positive output
Negative (return) output
C
D
B Input Terminals
Screw terminals
+
Positive input
Negative (return) input
Chassis ground can be used to bond the housing to PE
Ground this terminal to minimize high-frequency emissions.
C Output voltage potentiometer
Open the flap to set the output voltage. Factory set: 24.1V
D DC-OK LED (green)
On when the voltage on the output terminals is > 21V
B
13. TERMINALS AND WIRING
Type
Solid wire
Stranded wire
American wire gauge
Recommended tightening torque
Screwdriver
Wire stripping length
Screw terminals
0.5-6mm2
0.5-4mm2
20-10 AWG
1Nm, 9lb.in
3.5mm slotted or Pozidrive No 2
7mm / 0.275inch
Instructions:
a) Use appropriate copper cables that are designed for an operating temperature of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum.
b) Follow local and national installation codes and regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Up to two stranded wires with the same cross section are permitted in one connection point.
e) Ferrules are allowed but not required
f) In order to fulfill GL requirements, unused terminal spaces must be closed.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
14. EMC
The CE mark indicates conformance with EMC directive 89/336/EC, 93/68/EC and 2004/108/EC and the low-voltage
directive (LVD) 73/23/EC, 93/68/EC, 2006/95/EC. A detailed EMC Report is available on request.
EMC Immunity
Electrostatic discharge
Electromagnetic RF field
Fast transients (Burst)
EN 61000-6-2, EN 61000-6-1
EN 61000-4-2
Contact discharge
Air discharge
EN 61000-4-3
80MHz-2.7GHz
EN 61000-4-4
Input lines
Output lines
Signal lines
Surge voltage on input
EN 61000-4-5
Surge voltage on output
EN 61000-4-5
Conducted disturbance
Criterions:
EN 61000-4-6
+Æ+ / - Æ chassis ground
+Æ+ / - Æ chassis ground
0,15-80MHz
Generic standards
8kV
15kV
10V/m
4kV
2kV
2kV
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
1kV
2kV
500V
500V
10V
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
A: DC/DC converter shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. DC/DC converter might shut-down and restarts by itself. No damage or hazards will occur
to the DC/DC converter.
EMC Emission
Conducted emission
EN 61000-6-3, EN 61000-6-4
CISPR 16-1-2, CISPR 16-2-1
Generic standards
Input / output lines
(Limits for DC power ports)
Class B
Radiated emission
EN 55011, EN 55022
This device complies with FCC Part 15 rules.
Operation is subjected to the following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
Switching frequency
90kHz to 140kHz (Output current > 0.5A)
Input voltage and output current
dependent
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
15. ENVIRONMENT
Operational temperature
Output de-rating
Storage temperature
Humidity
-25°C to +70°C (-13°F to 158°F)
1.6W/°C
3W/°C
-40 to +85°C (-40°F to 185°F)
5 to 95% r.H.
Reduce output power according to Fig. 15-1
45-60°C (113°F to 140°F), see Fig. 15-1
60-70°C (140°F to 158°F), see Fig. 15-1
During storage and transportation
IEC 60068-2-30
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis
30g 6ms, 20g 11ms
3 bumps / direction, 18 bumps in total
0 to 6000m (0 to 20000ft)
IEC 60068-2-6
Do not energize while condensation is present
Vibration sinusoidal
Shock
Altitude
Output de-rating (for altitude)
Over-voltage category
7.5W/1000m or 5°C/1000m
III
II
2
Degree of pollution
Fig. 15-1 Output current vs. ambient temp.
Allowable Output
Current at 24V
6A
short
term
continuous
Allowable Output
Current at 24V
4
4
3
3
2
2
1
1
-25
0
20
40
short term
6A
5
Ambient Temperature
Reduce output power or ambient
temperature above 2000m sea level.
Above 2000m (6500ft), see Fig. 15-2
EN 50178, altitudes up to 2000m
Altitudes from 2000m to 6000m
EN 50178, non conductive
Fig. 15-2 Output current vs. altitude, 24V
5
0
IEC 60068-2-27
B
C
A
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 40°C
Altitude
0
60 70°C
0
2000
4000
6000m
The ambient temperature is defined 2cm below the unit.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
11/11
CD5.242
DC/DC Converter; 24V, 5A
CD–Series
16. PROTECTION FEATURES
Output protection
Output over-voltage protection
Electronically protected against overload, no-load and short-circuits
typ. 31Vdc
In case of an internal DC/DC converter fault, a redundant
max. 32Vdc
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Reverse input polarity protection
included
Unit does not start when input voltage is reversed
Output over-current protection
electronically limited
See Fig. 7-1
Degree of protection
IP 20
EN/IEC 60529
Penetration protection
> 3.5mm
E.g. screws, small parts
Over-temperature protection
yes
Output shut-down with automatic restart
Input transient protection
MOV
Metal Oxide Varistor
Internal input fuse
T5A H.B.C.
Not user replaceable
An audible noise may be heard during a no load, overload or short circuit event.
17. SAFETY
Input / output separation
SELV
IEC/EN 60950-1
PELV
EN 60204-1, EN 50178, IEC 60364-4-41
Double or reinforced insulation,
Max. allowed voltage between any input pin and ground: 60Vdc or 42.4Vac
II
PE (Protective Earth) connection not required
> 5MOhm
Input to output, 500Vdc
< 0.1Ohm
Between housing and Chassis Ground terminal
The leakage current which is produced by the DC/DC converter itself depends on
the input voltage ripple and need to be investigated in the final application.
For a smooth DC input voltage, the produced leakage current is less than 100µA.
Class of protection
Isolation resistance
Chassis Ground resistance
Touch current (leakage current)
18. DIELECTRIC STRENGTH
Fig. 18-1 Dielectric strength
Input
+
B
-
Output
A
Chassis
ground
+
C
-
Type test
60s
A
1500Vac
B
1500Vac
C
500Vac
Factory test
5s
1500Vac
1500Vac
500Vac
Field test
5s
1000Vac
1000Vac
500Vac
Type tests and factory tests:
Conducted by the manufacturer. Do not repeat test in field!
Rules for field test:
Use appropriate test equipment which applies the voltage
with a slow ramp! Connect all input poles together as well
as all output poles.
The output voltage is floating and has no ohmic connection to ground.
To fulfill the PELV requirements according to EN60204-1 § 6.4.1, it is recommend that either the + pole, the – pole or
any other part of the output circuit shall be connected to the protective earth system. This helps to avoid situations in
which a load starts unexpectedly or can not be switched off any more when an unnoticed earth faults occur.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
19. APPROVALS
IEC 60950-1
IECEE
CB Scheme,
Information Technology Equipment
CB SCHEME
UL 508
18WM
LISTED
IND. CONT. EQ.
LISTED E198865
Industrial Control Equipment
UL 60950-1
RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-1)
and Canada (C22.2 No. 60950)
Information Technology Equipment, Level 3
UL 1604
pending
RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and
Canada (C22.2 No. 213-M1987)
Hazardous Location Class I Div 2 T4 Groups A,B,C,D and
Class I Zone 2 Groups IIA, IIB and IIC
The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I
Zone 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for
Class I Division 2 environment. Do not disconnect equipment unless power has been switched
off. Wiring must be in accordance with Class I, Division 2 wiring methods of the National
Electrical Code, NFPA 70, and in accordance with other local or national codes.
CSA
pending
R
C
Marine
pending
182790
GL
CSA approval for Canada
CAN/CSA C22.2 No 107-1; CAN/ CSA 60950-1-03; UL60950-1
US
ABS
GL (Germanischer Lloyd) classified and ABS (American Bureau for
Shipping) PDA for marine and offshore applications.
Environmental category: C, EMC2
20. FULFILLED STANDARDS
EN 61558-2-17
Safety of Power Transformers
EN/IEC 60204-1
Safety of Electrical Equipment of Machines
EN/IEC 61131-2
Programmable Controllers
EN 50178, IEC 62103
Electronic Equipment in Power Installations
21. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
The unit conforms to the RoHS directive 2002/96/EC
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The materials used in our production process do not include the following toxic chemicals:
Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated
Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated
Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
22. PHYSICAL DIMENSIONS AND WEIGHT
Weight
DIN-Rail
425g / 0.94lb
Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the depth (102mm) to calculate the total required
installation depth.
Electronic files with mechanical data can be downloaded at www.pulspower.com
Fig. 22-1
Front view
Fig. 22-2
Side view
23. INSTALLATION AND OPERATION INSTRUCTIONS
Mounting:
Output terminal must be located on top and input terminal on the bottom. For other orientations see chapter 25.13.
An appropriate electrical and fire end-product enclosure should be considered in the end use application.
Cooling:
Convection cooled, no forced cooling required. Do not cover ventilation grill (e.g. cable conduits) by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently
with full power. In case the adjacent device is a heat source, 15mm clearance are recommended.
Risk of electrical shock, fire, personal injury or death!
Turn power off before working on the DC/DC converter. Protect against inadvertent re-powering.
Make sure the wiring is correct by following all local and national codes.
Do not open, modify or repair the unit.
Use caution to prevent any foreign objects from entering into the housing.
Do not use in wet locations or in areas where moisture or condensation can be expected.
Supplying source:
The inductance and resistance of the supplying network shall be below in Fig. 25-9 in chapter 25.10 to avoid resonant
effects on the input terminals. Please also check chapter 25.10.
Service parts:
The unit does not contain any service parts. The tripping of an internal fuse is caused by an internal fault. If damage
or malfunctioning should occur during operation, immediately turn power off and send unit to the factory for
inspection!
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
24. ACCESSORY
ZM1.WALL Wall mounting bracket
This bracket is used to mount specific Dimension units onto a flat surface without utilizing a DIN-Rail. The two
aluminum brackets and the black plastic slide of the unit have to be removed, so that the two steel brackets can be
mounted.
(Please note: Picture shows a different unit)
Fig. 24-1 ZM1.WALL Wall Mounting Bracket
Fig. 24-2 Assembled Wall Mounting Bracket
ZM11.SIDE Side mounting bracket
This bracket is used to mount specific Dimension units sideways with or without utilizing a DIN-Rail. The two
aluminum brackets and the black plastic slide of the unit have to be removed, so that the steel bracket can be
mounted.
For sideways DIN-rail mounting, the removed aluminum brackets and the black plastic slide need to be reinstalled on
the steel bracket.
(Please note: Pictures show a different unit)
Fig. 24-3 ZM11.SIDE Side Mounting Bracket
Fig. 24-4 Side Mounting with DIN-rail brackets
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25. APPLICATION NOTES
25.1. PEAK CURRENT CAPABILITY
Solenoids, contactors and pneumatic modules often have a steady state (sealed) coil and a pick-up coil. The inrush
current demand of the pick-up coil is several times higher than the steady state current and usually exceeds the
nominal output current (including the PowerBoost) The same situation applies, when starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch
circuit, the fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the
safe operation of subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the
DC/DC converter can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The
following two examples show typical voltage dips:
Fig. 25-1 Peak load 10A for 50ms, typ.
Output
Voltage
24V
10A
17.1V
Fig. 25-2 Peak load 20A for 5ms, typ.
24V
Output
Voltage
20A
11V
Output
Current
0.7A
Output
Current
0.7A
1ms/DIV
10ms/DIV
Peak load 10A (resistive) for 50ms
Output voltage dips from 24V to 17.1V.
Peak load 20A (resistive) for 5ms
Output voltage dips from 24V to 11V.
25.2. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the DC/DC converter. This feature is also
called return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This DC/DC converter is resistant and does not show malfunctioning when a load feeds back voltage to the DC/DC
converter. It does not matter, whether the DC/DC converter is on or off.
The maximum allowed feed back voltage is 30Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in chapter 7.
25.3. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of load, including unlimited capacitive and inductive loads.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25.4. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCBs or UL1077 circuit breakers) can be used for branch circuit protection.
Ensure that the MCB is also rated for DC voltage. The following tests show which circuit breakers the DC/DC converter
typically trips.
Circuit breakers have huge tolerances in their tripping behavior, therefore, these typical tests can only be used as a
recommendation or for comparing two different DC/DC converters. Furthermore, the loop impedance has a major
influence on whether a breaker trips or not. Two tests were performed, representing typical situations:
Test 1: Short circuit with S1 on the DC/DC converter end of the cable (loop impedance approx. 20mOhm)
Fig. 25-3 Branch protectors, test circuit 1
Parameters:
DC/DC
Converter
Input
Circuit
Breaker
I
Input voltage:
+
A- or Z- Characteristic::
B- Characteristic:
Load
DC -
0A
The following circuit breaker tripped during the test:
+
S1
24Vdc, load current:
-
equal or smaller 8A *)
no tripping ≥ 6A *)
no breaker available < 6A
equal or smaller 3A *)
C- Characteristic:
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 25-4 Branch protectors, test circuit 2
Parameters:
Input voltage:
DC/DC
Converter
AC
+
Circuit
Breaker
I
0A
The following circuit breaker tripped during the test:
R
A- or Z- Characteristic::
B- Characteristic:
+
S1
DC -
24Vdc, load current:
Load
C- Characteristic:
-
≤ 6A and R= 180mOhm *)
no tripping ≥ 6A *)
no breaker available < 6A
≤ 3A and R= 270mOhm *)
What does this resistance mean in wire length?
2
0.5mm
2
0.7mm
2
1.0mm
2
1.5mm
2
2.5mm
2
4.0mm
180mOhm
5.0m
7.0m
10m
15m
25m
40m
270mOhm
7.5m
10.5m
15m
23m
38m
60m
*) A list of the circuit breakers under test is available on request.
Example:
Which wire gauge must be used to trip a C-Characteristic circuit breaker with a rating of 3A? The load wire length is
21m.
Answer: A 3A C-Characteristic circuit breaker requires a loop impedance of less than 270mOhm (test results). The wire
2
length table shows that up to 23m wire with a cross section of 1.5mm are below 270mOhm. A wire not smaller than
2
1.5mm shall be used.
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25.5. SERIES OPERATION
DC/DC converters can be connected in series to increase the output voltage.
Instructions for use in series:
a) It is possible to connect as many units in series as needed,
providing the sum of the output does not exceed 150Vdc.
b) Voltages with a potential above 60Vdc are not SELV any more
and can be dangerous. Such voltages must be installed with a
protection against touching.
c)
For serial operation use DC/DC converters of the same type.
d) Earthing of the output is required when the sum of the output
voltage is above 60Vdc.
e) Keep an installation clearance of 15mm (left/right) between
two DC/DC converters and avoid installing the DC/DC
converters on top of each other.
Note: Avoid return voltage (e.g. from a decelerating motor or
battery) which is applied to the output terminals.
Fig. 25-5 Schematic for series operation
Unit A
Input
Output
+
+
Unit B
Load
Input
Output
+
-
Earth
(see notes)
25.6. PARALLEL USE TO INCREASE OUTPUT POWER
Several DC/DC converter can be paralleled to increase the output power.
Fig. 25-6 Schematic for parallel operation
Unit A
Fuse *)
Input
Output
+
-
Unit B
Fuse *)
Input
Output
+
-
+
Load
-
Instructions for parallel use:
a) Use only DC/DC converters from the same series (C-Series) or
consult PULS.
b) Adjust the output voltages of all power supplies to
approximately the same value (±200mV).
c)
A fuse (or diode) on the output is only required if more than
three units are connected in parallel.
d) Do not load terminals with more than 25A. Follow wiring
instructions according to chapter 25.7
e) Ensure that the ambient temperature of the power supply does
not exceed 45°C.
25.7. DAISY CHAINING OF OUTPUTS
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current
through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Fig. 25-7 Daisy chaining of outputs
Fig. 25-8 Using distribution terminals
max 25A!
Output
+ + - -
Output
+ + - -
+
-
Load
Output
+ + - -
Output
+ + - -
DC/DC
Converter
DC/DC
Converter
DC/DC
Converter
DC/DC
Converter
Input
Input
Input
Input
+
-
Load
Distribution
Terminals
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25.8. PARALLEL USE FOR 1+1 REDUNDANCY
DC/DC converters can be paralleled for 1+1 redundancy to gain a higher system availability. Redundant systems
require a certain amount of extra power to support the load in case one DC/DC converter unit fails. The simplest way
is to put two DC/DC converters in parallel. In case one converter fails, the other one is automatically able to support
the load current without any interruption.
Furthermore, redundant systems can be built by using a DC/DC converter powered from a battery and a power supply
with AC input.
-
Use the decoupling module YR2.DIODE in combination with two CD5.241-S1 and use the DC-OK signals of the
DC/DC converter to monitor a faulty unit or input voltage.
-
Use the redundancy module YRM2.DIODE in combination with two CD5.241 and use the DC-OK signals of the
redundancy module to monitor a faulty unit or input voltage.
Recommendations for building redundant power systems:
a) Use separate input fuses for each DC/DC converter.
b) Monitor the individual voltage sources of a redundant system. A DC-ok lamp and a DC-ok contact is included in
the redundancy module YRM2.DIODE and the DC/DC converter CD5.241-S1. This feature reports a faulty unit.
c)
When possible, connect each DC/DC converter to different power sources.
25.9. CHARGING OF BATTERIES
The power supply can be used for float-charging of lead-acid or maintenance free 24V VRLA batteries.
Instructions for charging batteries:
a) Ensure that the ambient temperature of the power supply does not exceed 50°C.
b) Set the output voltage on a disconnected load, very precisely to the end-of-charge voltage according to the
expected battery temperature.
End-of-charge voltage
Battery temperature
c)
d)
e)
f)
27.8V
10°C
27.5V
20°C
27.15V
30°C
26.8V
40°C
Use a 6A or 10A circuit breaker (or blocking diode ) between the power supply and the battery.
Ensure that the output current of the power supply is below the allowed charging current of the battery.
Use only matched batteries when putting 12V types in series.
The return current to the power supply is typ. 26.4mA at 25Vdc when the power supply is switched off (except in
case a blocking diode is utilized).
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25.10. REQUIREMENTS FOR THE SUPPLYING SOURCE
In certain circumstances, the input filter of the DC/DC converter can show a resonant effect which is caused by the
supplying network. Especially when additional external input filters are utilized, a superimposed AC voltage can be
generated on the input terminals of the DC/DC converter which might cause a malfunction of the unit. Therefore,
additional input filters are not recommended. To avoid the resonant effects, the minimal resistance of the supplying
network which depends on the inductance of the input network, shall be above the boundary curve in Fig. 25-9.
Fig. 25-9 Requirements for an input filter
stability
Resistance of the
supplying network
1 Ohm
(a)
(b)
100 mOhm
10 mOhm
(a) max.
(b) typ.
1 mOhm
0.1mH
1mH
10mH
Inductance of the supplying network
25.11. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 50A. External protection is only required if the supplying
branch has an ampacity greater than this. In some countries local regulations might apply so check local codes and
local requirements.
If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.
Ampacity
max.
min.
B-Characteristic
50A
6A
C-Characteristic
50A
6A
25.12. USE IN A TIGHTLY SEALED ENCLOSURE
When the DC/DC converter is installed in a tightly sealed enclosure, the temperature inside the enclosure will be
higher than the outside. The inside temperature defines the ambient temperature for the DC/DC converter.
Results from such an installation:
DC/DC converter is placed in the middle of the box, no other heat producing equipment inside the box
Enclosure:
Load:
Input:
Temperature inside the box:
Temperature outside the box:
Temperature rise:
Rittal Type IP66 Box PK 9516 100, plastic, 110x180x165mm
24V, 4A; (=80%) load is placed outside the box
48Vdc
42.8°C
(in the middle of the right side of the DC/DC converter with a distance of 2cm)
24.0°C
28.8K
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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Germany
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CD5.242
DC/DC Converter; 24V, 5A
CD–Series
25.13. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top requires a reduction in
continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction
influences the lifetime expectancy of the DC/DC converter. Therefore, two different derating curves for continuous
operation can be found below:
Curve A1
Curve A2
Recommended output current.
Max allowed output current (results approx. in half the lifetime expectancy of A1).
Fig. 25-10
Mounting
Orientation A
Standard
Orientation
Output Current
6A
5
4
3
2
1
0
10
OUTPUT
DC/DC
Converter
INPUT
Fig. 25-11
Mounting
Orientation B
(Upside down)
Ambient Temperature
20
30
40
60°C
50
Output Current
6A
5
4
3
2
1
0
10
INPUT
DC/DC
Converter
OUTPUT
Fig. 25-12
Mounting
Orientation C
(Table-top
mounting)
A2
A1
Ambient Temperature
20
30
40
60°C
50
Output Current
6A
5
4
3
2
1
0
10
Fig. 25-13
Mounting
Orientation D
(Horizontal cw)
A2
A1
Ambient Temperature
20
30
40
60°C
50
Output Current
OUTPUT
DC/DC
Converter
INPUT
6A
5
4
3
2
1
0
10
A2
A1
Ambient Temperature
20
30
40
60°C
50
INPUT
DC/DC
Converter
Output Current
OUTPUT
Fig. 25-14
Mounting
Orientation E
(Horizontal ccw)
A1
6A
5
4
3
2
1
0
10
A2
A1
Ambient Temperature
20
30
40
50
60°C
Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
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